Valve block assembly

ABSTRACT

A valve block assembly with internal delivery channels and a common outlet channel is provided. Access of reactants to the delivery channels is controlled by diaphragm valves, preferably equipped with relief grooves to accommodate deformation of the diaphragm. Reservoirs feeding the delivery channels have an inert atmosphere controlled by pressurizing and venting channels in the valve block. Exposure of plastic tubing to oxygen is kept to a minimum. The assembly is particularly adapted for use in a DNA or protein sequencer to supply reactants without cross-contamination or oxidative decomposition.

RELATED APPLICATION

This is a continuation, of application Ser. No. 07/964,297, filed Oct.21, 1992, now abandoned which is a division of application Ser. No.07/820,468, filed Jan. 14, 1992, now U.S. Pat. No. 5,316,034 which is acontinuation of application Ser. No. 07/396,684, filed Aug. 22, 1989,now U.S. Pat. No. 5,082,788; which is a division of application Ser. No.07/205,772, filed Jun. 13, 1988, now U.S. Pat. No. 4,911,195; which is acontinuation-in-part of application Ser. No. 06/901,327, filed Aug. 27,1986, now U.S. Pat. No. 4,773,446.

BACKGROUND OF THE INVENTION

This invention relates to a valve block assembly of the kind havingmultiple inlets and a single outlet. Such assemblies find particularapplication in protein sequencers.

Automated chemistry instrumentation has traditionally used manysubsystems to accomplish fluid handling. These subsystems includevalving, tubing, tubing connectors, manifolds and fluid reservoirs. Manytimes, the type of chemistry used in these external sources is sensitiveto contamination from internal or external sources so it is critical todesign the instrument so that contamination is eliminated or minimized.For example, in the chemistry used in protein sequencers, the so-calledEdman degradation, it is extremely important to exclude oxygen from thereaction. The Edman degradation consists of two principal chemicalreactions called the coupling reaction and the cleavage reaction. Duringthe coupling reaction, phenylisothiocyanate (PITC) reacts with theprotein amino groups in the presence of a base to form aphenylthiocarbamyl (PTC) derivative of the amino-terminal amino acid.The cleavage reaction results in the anilinothiazolinone (ATZ)derivative of the amino terminal amino acid being formed as it iscleaved from the protein chain. The PTC group is extremely sensitive todesulfurization by oxidation so it is imperative that the reaction beperformed in the absence of oxygen. If the PTC group is oxidized, thedegradation will halt because the ATZ cannot be formed.

To overcome the problem of oxygen contamination, it has become commonpractice to flush the reaction chamber with an inert gas such asnitrogen or argon. While this helps keep the chamber atmosphere oxygenfree, it does not prevent oxygen from entering the reaction chamber as adissolved gas in the reactants themselves. Since the chemicals used inthe Edman degradation are also very corrosive, all tubing in thefluid-handling system must be chemically inert. Unfortunately, thetubing, although extremely resistant to attack by the Edman chemicals,is also very porous to the oxygen in the atmosphere and the chemicalsbecome contaminated by the diffusing oxygen.

Previous protein sequencers have used tubing to connect remote deliveryvalves, pressure valves and venting valves to chemical reservoirs withthe result that oxygen sensitive chemicals are directly exposed to thediffusing oxygen, not only in the tubing, but also in the reservoirs.There is a direct pathway from the atmosphere through the tubing to thecontents of the reservoir from the exposed tubing. To help overcome thisproblem, it has been a common practice to add reducing agents to all ofthe chemical reservoirs. While this seems to help significantly, it isnot an ideal solution to the problem. The reducing agents contributespurious components which may interfere with the analysis of the aminoacid derivative produced by the sequencer. Also, the antioxidizingeffect of the reducing agents is relatively short-term. If the chemicalsin the tubing are exposed for a period of days, as in the case of anidle instrument, the chemical must be replaced for the performance ofthe Edman degradation is greatly compromised.

Another source of oxygen contamination is leaking at the junctionsbetween connecting tubing and other components of the fluid-handlingsystem. Previous fluid handling systems have made extensive use ofindividual components connected through tubing. Every connectionrepresents a potential source of trouble, not only from oxygencontamination but from poor performance due to variable flow rates in aleaking system. Also, since these chemicals may be corrosive orpoisonous, a leak represents a hazard to operators and to the instrumentitself.

Wittman-Liebold, U.S. Pat. No. 4,008,736 describes a valve arrangementin which a common conduit is formed in the valve block. All deliveryvalve sites lie on the same surface and are connected by zig-zaggingportions of the conduit. While this type of common conduit may becleaned by flushing, it cannot be claned easily with a wire. It is alsodifficult to machine.

Graffunder, U.S. Pat. No. 4,168,724 replaced the slider valves of the'736 patent with diaphragm valves. These valves are closed by fluidpressure in an actuator chamber adjacent to the diaphragm, and opened byevacuating the chamber. The zigzag sections of the common conduitintersect at the surface of the valve block. All delivery valve siteslie on the same surface.

This apparatus has several disadvantages. First, it is necessary toprovide vacuum and high pressure sources. Second, the diaphragm has atendency to cold flow into the common conduit at the point ofintersection, requiring that it be moved a greater distance in order toopen the valve. This in turn places greater demands on the evacuationsystem, and increases the wear and tear on the diaphragm.

Hunkapiller, U.S. Pat. No. 4,558,845 replaces the zigzag sections ofWittman-Liebold with straight sections which are easier to clean and tomachine. However, each valve site is placed on a separate block, and thecommon conduit is alternately a channel in a block and tubing exposed tothe atmosphere.

Hunkapiller also replaced Wittmann's actuation mechanism with a plungerthat is spring-biased to a closed position. A solenoid device is used todraw the plunger to an open position. Since Hunkapiller retains thenarrow access port of the previously described apparatus, his valve islikewise subject to the problem of membrane "cold flow".

SUMMARY OF THE INVENTION

This invention is directed to an integrated fluid-handling system whichavoids the undesirable features of prior devices. All of the subsystemsnormally found in previous systems have been integrated into one compactunit with the result that most of the tubing and connectors in priordevices have been eliminated.

The only exposed tubing leads from the gas regulators to the blockassembly and from the valve block assembly to the receiving vessel(reaction chamber). This reduces the exposure of sensitive chemicals tooxygen diffusing through the walls of exposed tubing or leaking in wherethe tubes are joined to other structures. In protein sequencers,delivery rates are low, so a particular reactant may be exposed todiffusing oxygen for hours before moving to the reaction chamber. Muchof the pressurizing and venting conduits for maintaining an inertatmosphere of appropriate pressure in the reservoirs is in the form ofchannels within the block. That part which is tubing is, with theaforestated exceptions, disposed within the controlled atmosphere of thereservoirs themselves.

In contrast, prior apparatus make heavy use of tubing, which isvulnerable to atmospheric attack. See Wittman, U.S. Pat. No. 3,959,307;Hood, U.S. Pat. No. 4,252,769.

To summarize, the present integrated system alleviates many of theproblems associated with automating the delivery of sensitive chemicalsto a reaction chamber. By locating the delivery conduits and connectorswithin the controlled atmosphere of the chemical reservoir or within thevalve block itself, exposure of the chemicals to diffusing oxygen iseliminated. The advantages of this approach include greater efficiencyof chemical reactions which are poisoned by oxidation of the reactantsand a much simpler and more reliable fluid-delivery system.

The common outlet conduit is composed of surface grooves at the valvesites and linear connecting sections which are open to the surface atboth ends. Thus, each section may be easily cleaned by passing a wirethrough the section. Also, these linear sections are easier to form thanthe zigzag sections of prior devices.

The grooves are less readily blocked by cold flowing of the diaphragm ofthe valve than is the narrow port of the prior devices.

If the side walls of the grooves diverge as they approach the surface,only a slight movement of the diaphragm away from the groove is neededto open fluid communication between the groove and the delivery port ateach valve site. The exit hole of the adjacent delivery channelpreferably has a conical or frusto-conical shape for similar reasons.Since only a slight separation of the diaphragm is needed, vacuum is notessential to valve operation.

Since each valve has its own diaphragm, the diaphragm may be selected ofa material which is appropriate for containing the contents of thecorresponding reservoir, and the diaphragm itself may be kept small.

The solenoid-holding block preferably has a two-tier design that reducescompressive forces on the valve block.

The upper tier holds the solenoid and the lower tier presses against themembrane. Compressive forces are mainly absorbed by the membrane ratherthan by the valve block. The lower tier also provides the plunger guidehole.

The lower tier compresses the periphery of the diaphragm, so that,absent other forces, the center would bulge into the plunger guide hole.The plunger is spring-biased to compress the center of the diaphragm.When the plunger is withdrawn by the solenoid, the center of thediaphragm springs back to the bulging position.

The lower tier of the solenoid-holding block preferably has a reliefgroove into which the membrane may "cold flow". Without this feature,the membrane may "cold flow" into the plunger hole, the delivery channeland the common channel, thereby impairing the operation of the valve.

Other advantages of the present valve block design will be apparent fromthe following description, claims, and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows an isometric view of the valve block assembly.

FIG. 2 is a sectional view of the valve block assembly (2A) and of thepresent valve when open (2B) and closed (2C).

FIG. 3 is a series of plan views (3A, 3B, 3C) of the valve block.

FIG. 4 is an isometric view of the interior of the valve block assembly,illustrating the various channels.

FIG. 5 is a view of the valve means with the relief groove (5B), ascompared to a view of a conventional valve (5A) without such a groove.

FIG. 6 is a series of side and end views of the present valve means anda conventional valve means, in open and closed positions, as follows:conventional system-valve closed, side view (6A), valve closed, end view(6B), valve open, end view (6C); present invention-valve closed, sideview (6D), valve open, end view (6E), valve closed, end view (6F).

FIG. 7 is a plan (7A) and side view (7B) of a second embodiment of thevalve block assembly.

DETAILED DESCRIPTION OF THE INVENTION

In a preferred embodiment, the valve block has two delivery valvesurfaces, best seen in FIG. 3. At least one valve site is provided oneach surface. The valve block provides a plurality of inlets and acommon outlet. At each valve site one finds an inlet channel 24, and anaccess to the common channel running to common outlet 18. The access isin the form of a groove 25 on the valve surface. The common channelconnects each valve site to a valve site on the other valve surface.Linear channel sections 26 connect the groove 25 of one valve site tothe groove of the next valve site on the other surface.

Since channel sections 26 are linear, and are open to both valvesurfaces, they may be cleared of any obstruction by running a fine wirethrough the section. Moreover, these sections do not present the problemof a dead volume interior to the valve block.

As seen in FIG. 1, fluid reservoirs 10 may be connected to the valveblock 16. These supply fluids (gases and liquids) are connected bytubing 11 and 13, respectively to delivery channels 24, as shown in FIG.2. Each delivery (feeder) channel communicates with one valve site atoutput end 24a. This output end 24a is spaced apart from the open groove25.

A diaphragm valve 19, 20, 21 is disposed at each valve site. When thevalve is closed, diaphragm 5 is pressed against output end 24a and opengroove 25, so fluid cannot pass out of the delivery channel and into thecommon channel. However, the diaphragm merely covers and does not plugthe groove, so fluid already in the common channel but upstream of thevalve may flow through the groove and on downstream. Opening deliveryvalve 19 allows pressurized fluid from channel 24 to leak into groove25. Preferably, the groove has a "V-shaped" or "rounded V-shaped"cross-section, so that only a small movement of the diaphragm is neededto permit this flow.

The solenoid-holding block 4 is internally threaded to accept a standardsolenoid 1. The unusual two-tiered design allows these blocks to besecured directly to the aluminum cradle 15 surface with screws throughthe upper tier. The lower cylindrical tier extends inside the aluminumcradle 15 to make the seal at the valve block 16 surface by pressingagainst the captive membrane 5. This design also ensures precisealignment of the solenoid plunger 3 over the channel entry/exit holes25,24 in the valve block 16 because the cylindrical lower tier can bemade perfectly concentric with the plunger guide hole 4b.

Another advantage of this two-tiered design is that the solenoid-holdingblock 4 never comes into direct contact with the valve block 16material. This is very important because valve blocks are made fromchemically resistant thermoplastics which all cold-flow when subjectedto mechanical stress. A design which puts any part of a solenoid-holdingblock directly on the plastic can change the mechanical properties ofthe valve, especially if the plastic material is heated or exposed tochemicals which even mildly attack it.

In our design, the only thing under compression in this critical area isthe membrane seal 5 so negligible mechanical stress is placed on thevalve block material 16. A controlled amount of compressive force can beapplied to this membrane 5 by machining the solenoid-holding block 4lower tier to the appropriate length. For example, if the membrane 5 is0.020" thick and the lower tier extends to within 0.015" of the valveblock 16 surface, 0.005" compression is applied when thesolenoid-holding block 4 is secured into position.

The relief groove 4a in the lower tier surface accommodates membranematerial 5 which would otherwise cold-flow into the plunger guide hole4b. If too much material flows into the plunger guide hole 4b, it willovercome the plunger spring 2 force and jam the plunger 3 upwards,preventing the valve from working (see FIG. 5).

While this recess is preferably in the form of a groove, it may takeother forms which provide a relief volume into which the stresseddiaphragm may flow.

A controlled amount of deformation is desirable since excess materialwithin the plunger guide hole 4b acts as a spring and helps the membrane5 lift. The relief groove 4a, while not essential, is preferred becauseit prevents overcompression of this material. The ideal balance iscalculated by adjusting the parameters of membrane compression andrelief groove 4a internal volume for a given guide hole 4b diameter.

The self-assisting action of the membrane is one key element in reliablevalve operation. The entire solenoid-holding block 4 is designed to takeadvantage of this self-assisting action. Previous zero-dead-volumedesigns have required either a vacuum/pressure or vacuum/spring membraneactuation for reliable operation. Our design takes advantage of theenergy stored in the compressed membrane to help lift it from thesealing surface. This is extremely important since it allows us to doaway with awkward and expensive vacuum systems to "assist" the valves.In addition, it makes for a much less complicated solenoid/plungerarrangement since it does not have to be vacuum-tight.

Also, all channels at or terminating at the valve block 16 sealingsurfaces are countersunk 27 so that a conical or V-shaped depression isformed at the surface. This allows a good seal and ensures that coldflow of the membrane 5 into the valve channel openings will formcomplementary conical or V-shaped protrusions which will move out of thechannel easily when the valve is actuated. Without the conical orV-shaped countersink, the membrane 5 will cold-flow in a cylindricalshape and effectively plug the channel. This cylindrical plug must liftentirely out of the channel before fluid can flow because the internalsurfaces of the valve channel and the membrane plug cannot separate. Theconical or V-shape formed by our design will allow fluid to flow as soonas the membrane 5 moves because the two surfaces will instantly separate(see FIG. 6).

The fluid reservoirs attach directly to a valve block assembly whichcontains the valving and internal channeling to control flow fromreservoir to reaction chamber as well as pressurization and venting ofthe reservoirs. Also included is the channeling to a venting manifold.

All tubing which contains fluid from the reservoirs are located withinthe reservoir itself or within the valve block's internal channels. Thevalve controlling the flow of this fluid is part of the assembly whichreceives the reservoir and communicates with the reservoir only throughchannels internal to the valve block assembly. This arrangement leavesno way for atmospheric oxygen to enter the system by diffusion throughporous tubing.

Likewise, the two other valves in the system, the reservoirpressurization valve and the reservoir venting valve, are mounteddirectly on the valve block assembly. The pressurization valvecommunicates with the reservoir only through channels within the valveblock or tubing contained within the reservoir. The tubing needed tobring pressurized gas from a regulator to the valve may be of anonporous material such as steel or aluminum since only inert gas flowsinto the tubing. Even if this tubing is porous, when the pressurizationvalve is closed there is no pathway for diffusing oxygen to reach thereservoir. Any oxygen which has entered the gas line may be purged outof the system by merely opening the pressure and vent valvessimultaneously for a short time before delivery of the fluid to thereaction chamber.

The venting valve communicates with the reservoir through a channelwithin the valve block assembly. The valve communicates with the ventmanifold in a similar manner. Part of the upper aluminum cover of thevalve block assembly also serves as the vent manifold which matesdirectly to the valve block through O-ring seals. A channel within theupper cover provides a route from the valve block to the manifold. Themanifold is continually flushed with an inert gas so that even when thevent valve is open, there is no way for oxygen to enter the system.

The reaction chamber which receives the chemical reactants from thefluid reservoirs may be mounted directly on the valve block assembly orremotely connected through a single piece of tubing. If the reactionchamber is to be heated, a remote configuration is preferred so thatgood temperature isolation is maintained between the fluids in thereservoirs and the reaction chamber. In practice, the single piece ofconnecting tubing between the valve block assembly and the reactionchamber does not represent a serious compromise in the design sincefluids are moving through this conduct and are never exposed todiffusing oxygen for extended periods of time. The tubing and thereaction chamber are always flushed with inert gas before fluids fromthe reservoirs enter the tubing. A protein sequencer is an example of aninstrument which might use this design.

If the reaction chamber is to be maintained at room temperature, it maybe connected directly to the valve block assembly through a sealingstructure not exposed to the atmosphere. This may be the case in a DNAsynthesizer, for example, where a heated chamber is not necessary butultra-low exposure of oxygen to the chemicals is also critical.

All chemically-resistant tubing which contains the reactant fluids islocated within the inert atmosphere of the reservoirs. Connection ofthis tubing to the valve block is made by stretching one end of thetubing slightly to decrease its diameter then pulling the tubing througha cylindrical fitting with a hole slightly smaller than the diameter ofthe unstretched tubing. The tubing is pulled through this hole until theunstretched portion makes a gas-tight interference fit. The excesstubing protruding from one end of the fitting is cut flush and thetubing protruding from one end of the fitting is cut to length suitablefor insertion into the chemical reservoir. A hole of appropriatediameter is countersunk directly into the valve block channel and thefitting is pressed in.

The tubing 11 and 13 in the reservoirs 10 are exposed only to acontrolled atmosphere. When pressure valves are opened, inert gas entersthe valve block at inlets 9 and directed through channels 22 into thetubing 12 of reservoirs 10. Excess gases are vented through channels 23in vent manifold 6 when vent valves 20 are opened. The gases vented,which may be noxious, are routed to one or more vents and removed fromthe apparatus. Inert O-rings 28 on the bottom of valve block 16 providea gas-tight-seal where the reservoirs 10 are screwed into inert bottlecaps 29 of lower aluminum cradle 15 of the block 16.

While, preferably, a single inert atmosphere is supplied to allreservoirs, it is possible to provide different reservoirs withdifferent gases. Also, it is possible to eliminate tubing 12 and permitthe channels 22 to communicate directly with reservoirs 10.

Numerous modifications will be apparent to those of ordinary skill inthe art. The tube leading from the gas regulators may be made ofnonporous metal. The tubing running from the valve block assembly to thereaction chamber may be eliminated by mounting the reaction chamber onthe valve block assembly. (A detached reaction chamber is, however,easier to heat.)

In another embodiment (FIG. 7), the valve body provides more than twovalve surfaces. As diagrammed, the valve body is octagonal, with each ofthe eight sides providing a valve site. The common channel comprises aseries of linear intervalve sections, each section running from one sideto an adjacent side. It terminates in a section running from the finalvalve site to the center, where an axial outlet channel is located. Ateach valve site, one may provide connecting grooves as taught above, orprovide intervalve sections which intersect at the valve surface astaught by Hunkapiller.

In another modification, the common channel of the valve block isprovided with a common inlet "upstream" of the feeder channels. Thisinlet may be helpful in a number of respects. First, it can be used tointroduce a fluid which will clean or dry the common channel. Second,the common outlet of one valve block could be connected to the commoninlet of another. If desired, this inlet may be valved.

We claim:
 1. A diaphragm valve for use in a valve assembly whichcomprises a valve block defining fluid passageways having openings in anupper surface of the block, a diaphragm means supported on the uppersurface and having a central portion disposed over said openings, aperipheral portion surrounding the central portion apart from saidopenings, movable plunger means spaced apart from the upper surface ofthe block for selectively compressing the central portion, a plungerseat supporting the movable plunger means and disposed over theperipheral portion of the diaphragm and having a gripping surface meansfor gripping and thereby compressing the peripheral portion of thediphragm, whereby the central portion is urged away from said openings,tending to bulge toward the movble plunger means in an open valveposition in the absence of fluid pressure, said plunger means beingadapted to maintain said central portion in a compressed position, thevalve being closed when the central diaphragm portion is compressed, anda relief groove means, isolated from said fluid passageways, located incontact with said peripheral portion of the diaphragm means between theplunger seat and the valve block, into which diaphragm material may flowunder stress.
 2. The valve means of claim 1 wherein the plunger means isbiased toward the valve-closing position.
 3. The valve means of claim 2,furtheer providing solenoid means for withdrawing the plunger meanstoward the valve-opening position.